DBF Machining Centers DBF 630 / 800
2 DBF Machining Centers Turning / drilling / milling The Horizontal Machining Centers HEC 500 / 630 / 800 Athletic can be used as all-round machining centers in a versatile and highly efficient manner. A further increase in flexibility and efficiency was realized thanks to the development of the machining centers DBF 630 and DBF 800 on the basis of the Athletic series. Thanks to the integrated DBF spindle head, the complex production in the processes turning, drilling and milling can be realized in one single workspace. The goal of complete machining in one clamping set-up on one machine is optimally reached thanks to the Horizontal Machining Centers DBF 630 and DBF 800.
DBF Machining Centers 3 Application ÌÌ Complex turning, drilling and milling of housing-shaped and prismatic work pieces with an interference diameter of up to 1,400 mm in one clamping operation ÌÌ Cutting of different work pieces in light metal, cast and steel design from batch size 1 to mass production ÌÌ Comprehensive turning operations: external turning face turning internal face turning internal plain turning and relieving ÌÌ Use in the fields of aerospace, transport, industry and energy Technological benefits ÌÌ Reduction of production and processing times: complete machining in the processes turning, drilling and milling ÌÌ High procedural integration: combination of the technologies of single machines in one workspace ÌÌ Reduction of non-productive times: high dynamics in the adjustment axes and in tool and work piece handling ÌÌ Precision with long-term accuracy: production with true running and axial run-out accuracy of 5 6 µm ÌÌ Reduction of the tooling times: clamping and unclamping of the tools during primary processing time at the clamping station ÌÌ Personalized production solutions: optimal realization of special customer requirements thanks to modular machine design ÌÌ Minimization of the maintenance and operating costs: comprehensive dispositioning facilities and monitoring devices for the entire system and high energy efficiency of the machining centers
4 DBF Machining Centers Advance through innovation Turning Drilling Thermal machine stability FEM-optimized main subassemblies with thermo-symmetric design for high static and dynamic stiffness Short installation times and low assembly costs Compact design for complete transport and installation with low requirements for foundation work High machining and long-term accuracy Use of high-precision subassemblies such as profiled rail guides in the linear axes, ball screw drives with counter bearing, hydraulic weight compensation for vertical support adjustment, absolute, direct position measuring systems and angle measuring systems. Optimal conditions for dry machining Safe and quick chip removal by means of a wide chip conveyor and vertical guide plates to avoid chip clusters in the workspace. Complete machining by means of turning/drilling/milling DBF spindle head, consisting of a face plate with integrated spindle and CNC-controlled radial facing slide for turning, drilling and milling High process reliability Work pieces in gantry design with guideways, ball screw drives and measuring systems, not being influenced by chips and coolant Precise multi-side machining NC rotary table with max. 70/60 rpm, input resolution 0.001 degrees, max. positioning scatter band Psmax 3, max. reversal error Umax 2 Reduction of tooling times Clamping and unclamping of work pieces during primary processing time at a separate clamping station.
DBF Machining Centers 5 Milling Innovative tool handling ÌÌ Chain magazine with 60, 80 or 120 storage places for tools with diameters of up to 325 mm and a length of up to 700 mm (turning operation: Ø 500 mm, width 200 mm) ÌÌ Tower magazine for max. 320 tools with a diameter of up to 250 mm and a length of up to 700 mm (turning operation: Ø 500 mm, width 200 mm) ÌÌ Tool change in the tower magazine during primary processing time User-friendly work piece handling ÌÌ Turnable clamping station with 4 90 degrees of indexing ÌÌ Coupling unit for hydraulic clamping devices (6 channels, 30 240 bar) ÌÌ Hydraulic lifting/pivoting changer for automatic pallet change Reduction of non-productive times ÌÌ High dynamics during tool and work piece handling and in the adjustment axes ÌÌ Hydraulic tool double-arm gripper and arrangement parallel to the spindle of the tools inside the magazine Most modern process control and monitoring ÌÌ CNC control Sinumerik 840 D solution Line or Fanuc Series 31 i each with integrated PLC and digital propulsion technology ÌÌ Monitoring of life and number of pieces ÌÌ Tool identification ÌÌ Tool break-down checking during primary processing time ÌÌ Tool-specific capacity utilization monitoring of the work spindle drive and the rotary table drive resp. ÌÌ Speed monitoring of the tools ÌÌ Optical measuring probe ÌÌ ARTIS tool and process monitoring Low maintenance and operating costs ÌÌ Modular service and diagnostic system SAM to improve the machine uptime, fast error diagnosis, data collection and statistics ÌÌ Brankamp-CMS Monitoring System for collision detection Expansion into Flexible Manufacturing Systems Linear storage unit for pallets with stacking crane, 6 storage places (DBF 800) and 10 storage places (DBF 630) for machine pallets, a loading and unloading station and master control (the storage places and clamping stations are optionally expandable)
6 DBF Machining Centers Power / precision / efficiency Thermo-symmetric machine design The machining centers have a cross-bed design with optimized main subassemblies. This compact design with integration of hydraulic and pneumatic subassemblies into the basic machine ensures complete transport, installation with low requirements for foundation work and thus short installation and commissioning periods. As a requirement for the high pallet loading mass of up to 2,500 kg and the dynamics of the adjustment axes, the work piece side of the centers is realized in gantry design with two feed drives. Guideways, ball screw drives and measuring systems cannot be influenced by chips and coolant in order to increase process reliability and process accuracy. A hydraulic weight compensation for the vertical axis increases precision during machining extends the service life and increases dynamics. High-precision functional groups Long-term tested subassemblies such as profiled rail guides with prestressed sealed guiding carriages in all linear axes and low-backlash digital AC-feed drives with ball screw drives and counter bearing ensure high adjustment and acceleration values, work piece accuracy of class IT 5 and long-term accuracy. Positioning and angle measuring is realized by means of absolute, direct measuring systems with protected housing and supplied with compressed air. A high positioning accuracy of the NC rotary table is ensured thanks to hydraulic clamping of the table and by means of compressed air application onto the table s internal space in order to avoid contamination. Flexible and time-saving tool handling In the standard version, tool storage is realized in the chain magazine with 60, 80 or 120 places for tools with a diameter of up to 325 mm and a length of up to 700 mm. For requirements for higher tool amounts, the machining centers can be optionally equipped with tower magazines for max. 320 tools. The tower magazines distinguish themselves by their low space requirement at highest tool density, the reduction of tooling times thanks to tool change during primary processing time and a high user comfort. The hydraulically functioning double-arm gripper, the arrangement parallel to the spindle of the tool inside the magazine and an optimized changing procedure ensure shortest chip-to-chip times. Tool identification, tool break-down checking and monitoring of the toolspecific speeds are a part of the modern tool management.
DBF Machining Centers 7 Chain magazine for tools with a diameter of up to 325 mm and a length of up to 700 m Machine design with tower magazine Comfortable tool handling The tools are clamped, re-clamped and unclamped at the clamping station during primary processing time. The clamping station, which is turnable and indexable by 4 90 degrees facilitates tooling on the fixture and on the work piece. The square-shaped or rectangular work piece pallets which are adapted to their respective tasks can be delivered in the dimensions 630 630 mm to 1,000 800 mm with tapped holes and T-grooves. For hydraulic clamping devices, the table pallets can be upgraded with a coupling unit for hydraulic clamping systems of 30 240 bar. A hydraulic lifting/pivoting device changes from the clamping station to the workspace quickly and automatically. In order to increase the flexibility and to ensure unattended production, the machining centers equipped with pallet linear storage unit are expandable. Optimal cutting conditions The machining centers provide ideal conditions for wet and dry machining. For wet machining, the coolant is supplied via the spindle and tool center at a pressure of max. 70 bar or at 50 l/min via nozzles. Depending on the cutting material, the coolant unit can be optionally equipped with vacuum slotted screen, fleece gravity filter or rotary vacuum filter. Temperature stabilization for the coolant is additionally available. The chips are discharged out of the workspace quickly and safely via the wide chip conveyor in scraper or link conveyor design, which is arranged centrally underneath the machine bed. Vertically arranged guide plates in the workspace prevent the formation of chip clusters and thus create good conditions for dry machining. In order to further improve the working and operating quality, the machining centers can be complemented by a splash shower for cleaning the work pieces, by a workspace and cover rinsing device, emission suction and a fire protection package for machining magnesium alloys.
8 DBF Machining Centers Internal and face turning work at the valve housing External and face turning work at steering pivot pins of a truck Turning, drilling and milling by means of DBF spindle head The DBF head ensures complete machining in the processes turning, drilling and milling on one machining center in the fit quality IT 5 with high surface quality. The spindle head consists of a face plate with integrated work spindle and a CNC-controlled radial facing slide. For turning on a fixed work piece, the rotating lathe tool can be radially adjusted by ± 35 mm. A leveling compound integrated into the head compensates the imbalance and thus ensures an axial run-out and true running accuracy of 5 6 µm. For drilling and milling applications, the work spindle is arranged in central position. The high drive power of max. 45 kw and the max. torque of 1,700 Nm ensure drilling into solid materials with a diameter of up to 100 mm. Besides external, internal and face turning, conical and contour turning are also possible thanks to the full-value NC axis of the radial facing slide. The coolant supply through the spindle center provides all turning, drilling and milling tools. The DBF spindle head ensures high procedural integration for each clamping operation. The complete machining on only one machine and the omission of re-clamping work increase the work piece accuracy and reduce the production and processing time.
DBF Machining Centers 9 Technology examples Duty profile ÌÌ Flexible production and complex unit parts in a great variety of versions with milling, drilling and turning of solid material X6 CrNiMoTi 17-12-2 ÌÌ Increased requirements for accuracy and surface quality, in particular when machining the seal seats. ÌÌ Required machine accuracy according to VDI/DGQ 3441: Position uncertainty P < 0.015 mm, Positioning scatter band Psmedium < 0.006 mm ÌÌ Reduction of the number of machine tools and clamping operations ÌÌ Reduction of production and processing times Solution ÌÌ Use of the Horizontal Machining Center DBF 800 with the specification: ÌÌ DBF spindle head (45 kw/1,700 Nm/ max. 3,500 rpm) ÌÌ Tool tower magazine with 320 storage places ÌÌ Pallet linear storage unit with 6 pallet places ÌÌ Production technology ÌÌ Complex production in one single clamping operation ÌÌ Milling with face-milling cutter Ø 125 mm, HSC-milling cutter Ø 125 mm with a feed rate of 5 000 mm/min and insert endmill Ø 50 mm ÌÌ Solid drilling Ø 70 mm ÌÌ Turning with turning tool Ø 89 mm and external turning tool Ø 300 mm Customer benefits ÌÌ Reduction of the production time by 77 % thanks to ready-for-assembly complete machining in one clamping set-up ÌÌ Reduction of processing times by 95 % thanks to production on one single Machining Center DBF 800. ÌÌ Minimization of non-productive times thanks to high dynamics during automatic tool exchange ÌÌ Unattended production thanks to pallet storage system and high tool storage capacity ÌÌ Machine accuracy (P = 0.008 mm/ Psmedium = 0.002 mm) ensures high work piece precision
10 DBF Machining Centers Duty profile ÌÌ Complete production of valve housings in a great variety of designs for gas turbines for the construction of power stations. ÌÌ Ready-for-assembly machining of the valves made of high-alloyed steel casting for high pressures and temperatures ÌÌ Use of high-speed spindles and angular milling heads ÌÌ Production processes turning, drilling and milling with a precision of class IT 5 Solution ÌÌ Production on Horizontal Machining Center DBF 800 with ÌÌ DBF spindle head (45 kw/1,700 Nm/ max. 3,500 rpm) ÌÌ Chain magazine for max. 80 tools up to Ø 325 mm and a length of up to 700 mm ÌÌ Telescopic torque support for the use of additional units (high-speed spindle/angular milling heads) Customer benefits ÌÌ Complete machining in one clamping set-up ÌÌ Reduction of production and processing times ÌÌ High flexibility during machining of the valve housings in great variety of versions ÌÌ Reduction of the non-productive times thanks to high dynamics during tool and work piece handling
DBF Machining Centers 11 Technical Data Values in brackets = option DBF 630 DBF 800 Design work spindle Horizontal Horizontal Design table NC rotary table NC rotary table Clamping surface/perf. pallet DIN 55201 mm 630 630 (800 630) 800 800 (1,000 800) Max. load kg 1,500 2,000 (2,500) Max. rotational speed rpm 70 60 Input and display resolution degree 0.001 0.001 Interference diameter mm 1,250 1,400 Automatic pallet change Number of changeable pallets basic machine 2 2 Max. pallet changing time s 14 18 Adjustment ranges Longitudinal adjustment X mm 1,070 1,320 Vertical adjustment support Y mm 870 1,070 Cross adjustment table Z mm 1,200 1,300 Radial adjustment lathe tool U mm ± 35 ± 35 Work spindle/dbf spindle Drive power 100 % c.d.f. kw 45 45 Torque 100 % c.d.f. Nm 1,700 1,700 Speed rang, turning rpm 50 1,200 50 1,200 Max. speed, drilling/milling rpm 3,500 3,500 Tool holder HSK-A 100 (SK 50 Form B/BT) HSK-A 100 (SK 50 Form B/BT) Tool change Magazine design Chain (Tower) Chain (Tower) Magazine storage places 60 (80/120) (180/240/320) 60(80/120) (180/240/320) Max. tool diameter mm 325 (250) 325 (250) Max. tool length mm 700 (450/700) 700 (450/700) Max. tool mass kg 35 (35) 35 (35) Max. tool dimensions, turning Diameter/width mm 500/200 (500/200) 500/200 (500/200) Max. tool mass, turning kg 25 (25) 25 (25) Chip-to-chip time VDI 2852 s 8 (8) 8 (8) Movement speed Feed range X/Y/Z, stepless mm/min 1 40,000/40,000/60,000 1 40,000/40,000/60,000 Fast motion X/Y/Z m/min 40/40/60 40/40/60 Feed force X/Y/Z 60% c.d.f. kn 22/18/22 22/18/22 Coolant device Supply via nozzles Output l/min 50 50 Pressure bar 2 2 Supply through spindle center Output l/min 30 30 Pressure 15 (50/70) 15 (50/70) Machine accuracy VDI/DGQ 3441 Linear axes X/Y/Z Max. position uncertainty P[Tp] mm 0.006 0.006 Max. positioning scatter band Psmax mm 0.004 0.004 Max. reversal error Umax mm 0.003 0.003 NC rotary table Max. position uncertainty P[Tp] sec 6 (4) 6 (4) Max. positioning scatter band Psmax sec 4 (3) 4 (3) Max. reversal error Umax sec 3 (2) 3 (2) U-axis Max. position uncertainty P[Tp] mm 0.015 0.015 Position scatter band Psmax mm 0.007 0.007 Dimensions and weights Length width height m 8.10 5.35 4.15 8.50 5.50 4.15 Weight kg 28,200 32,000 CNC control Sinumerik 840 D solution Line (Fanuc 31 i) Sinumerik 840 D solution Line (Fanuc 31 i)
_ Berthiez Bumotec Dörries Droop + Rein Heckert Scharmann SIP Starrag TTL WMW Heckert GmbH Otto-Schmerbach-Strasse 15/17 09117 Chemnitz Germany P +49 371 836 22 88 F +49 371 836 23 98 sales.heckert@starrag.com www.starrag.com by Heckert, 06/2014 All specifications in this brochure are deemed to be contractually guaranteed if they are confirmed by us explicitly and individually in writing.